Cartridge Assembly Module for High Pressure Fluid Systems
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Solution Overview
Problem
Conventional high pressure fluid end assemblies are difficult to service due to complex designs, requiring removal of large and unwieldy manifolds, leading to time-consuming maintenance and potential operator errors, especially in high-pressure applications where safety is a concern.
Innovation Solution
The introduction of a Cartridge Assembly Module (CAM) that allows for selective removal and replacement without disassembling the discharge manifold, featuring a handle for ergonomic manipulation, quick couplers for tool-free servicing, and a lubrication system that minimizes external plumbing, enhancing safety and reducing maintenance time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional fluid end assemblies are serviced by removing the discharge manifold, then high wear components can be accessed and replaced, but the servicing process becomes extremely time consuming and difficult due to the large size and weight of the manifold
Solution Approach 1:
The fluid end assembly is divided into modular components: a reusable discharge manifold and replaceable cartridge assemblies. Each cartridge assembly contains specific high wear components (valve seat, seal cartridge, plunger) that can be independently serviced. This segmentation allows the manifold to remain installed while cartridges are quickly swapped, eliminating the time-consuming process of removing and reinstalling the entire manifold assembly.
Solution Approach 2:
The high wear components are extracted from the traditional integrated manifold design and placed into separate removable cartridge assemblies. This extraction enables servicing of individual cartridges without affecting the manifold or other system components, dramatically reducing maintenance time and complexity.
2Ease of repair
If the discharge manifold is removed to service high wear components, then internal components can be accessed, but the manifold must be carefully re-mounted with multiple bolts tightened to precise torque
Solution Approach 1:
The assembly is segmented into a permanent manifold and removable cartridges. The cartridges are designed with simplified retention mechanisms (retainer elements) that replace the need for multiple high-torque bolts, reducing reassembly complexity while maintaining component accessibility.
Solution Approach 2:
The complex multi-bolt manifold attachment system is extracted and replaced with a simpler cartridge retention system. The cartridges use retainer elements that can be quickly installed and removed without requiring precision torqueing of multiple bolts, significantly reducing assembly complexity.
3Device complexity
If a single discharge port is used in the manifold, then the assembly is simpler, but customization is limited and may require replacement of the entire manifold
Solution Approach 1:
The discharge port configuration is segmented from the manifold and integrated into the replaceable cartridge assemblies. This allows different cartridge types with various port configurations to be swapped based on application needs, providing customization without modifying or replacing the entire manifold.
Solution Approach 2:
The manifold is designed as a universal platform that can accommodate multiple cartridge types through standardized interfaces. This multi-functionality allows a single manifold to support various discharge configurations by simply changing the cartridges, eliminating the need for custom manifold designs for different applications.
4Reliability
If rupture discs are mounted in the manifold, then protection against excessive pressure is provided, but operator error in selecting the wrong rupture disc is frequently increased due to time pressure and sensory overloading
Solution Approach 1:
Rupture disc selection is segmented into the cartridge assembly level rather than the manifold level. Each cartridge is pre-configured with rupture discs matched to its specific pressure rating and application. This segmentation ensures that operators select the correct rupture disc at the cartridge level, reducing errors caused by time pressure and sensory overloading at the manifold level.
Solution Approach 2:
The cartridge assembly acts as an intermediary between the operator and the rupture disc selection process. By pre-matching rupture discs to specific cartridges based on pressure ratings and applications, the system mediates against operator error, ensuring correct selection without requiring operators to make complex decisions under pressure.
Data Source
AI summary
A high pressure fluid system including enhanced safety, maintenance and servicing features. The system can include a CAM assembly module, having a valve seat assembly, seal cartridge assembly and inlet manifold, that is easily installed in and removed from a frame and/discharge manifold as a single unit. A discharge manifold can isolate different pressure rated passageways of the system, and multiple rupture discs associated with the same. A discharge manifold end plate can be included to provide ease of repair of discharge outlets and to establish a plumbing system for the rupture discs. A quick coupler can facilitate connection between a plunger of the seal cartridge assembly and a cross head stub connected to a power frame. A lubrication valve assembly can provide and meter lubrication from a high pressure inlet source to a plunger and packing of the seal cartridge assembly.